BUELL ZUMO GLOBAL POSITIONING SYSTEM (GPS) KIT
J045842008-06-24
GENERAL
Kit Number
92393-08Y
Models
For model fitment information, see the Buell Accessories and Parts Countertop Reference Guide (CRG) or the Accessories section of www.buell.com (English only).
Electrical Overload
NOTICE
It is possible to overload your motorcycle's charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle's charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Buell dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00249b)
WARNINGWhen installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (00310a)
The Buell® Zumo® requires up to 1.08 amps additional current from the electrical system.
INSTALLATION
NOTE
Do not use solvent-based chemicals or waxes directly on the plastic or rubber components as they can affect the overall performance and appearance of the plastic and rubber.
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
| 1. | Refer to the owner's manual, and follow the instructions given to remove the seat. Unthread the fastener and remove the negative (black) battery cable from the negative (-) battery terminal. | |||||
| 2. | Remove and discard the front brake master cylinder clamp mounting screws. Remove the master cylinder clamp. | |||||
| 3. | See Figure 2. Obtain the GPS cradle (3), ram mount base (8), four Phillips flat-head screws (4) and four lock nuts (5) from the kit. Assemble the cradle to the base with the screws and nuts, and tighten to 1.6–2.3 N·m (14–20 in-lbs). | |||||
| 4. | Obtain the ram mount arm (9) and mounting post (10) from the kit. With the weather cap (A) at the bottom, assemble the ram mount base and post ball mounts into the sockets of the arm. Tighten enough to hold the three pieces in position. | |||||
| 5. | Obtain the two hex socket button-head screws (11) and two spacers (12) from the kit. Insert the screws into the mounting post, through the slots. Place a spacer over the threads of each screw. Insert the screw threads into the holes in the front brake master cylinder clamp removed earlier. | |||||
| 6. | Position the ram mount post and front brake master cylinder clamp onto the right-side handlebar, and thread the screws into the tapped holes in the front brake master cylinder housing. Adjust the hand lever position for rider comfort and posture, then tighten the screws to 9–10 N·m (80–90 in-lbs). | |||||
| 7. | Obtain the Buell Zumo harness (13) and two small screws (6) from the kit. Plug the round 4-pin DIN connector (D) on the harness into the front of the cradle, and fasten securely with the mounting screws. Route the unconnected end of the harness into the area behind the flyscreen/windscreen, following the existing wiring from the right-side handlebar switches. | |||||
| 8. | Remove the flyscreen/windscreen assembly from the vehicle by removing the six screws and washers, and set these items aside. | 
Figure 1. Auxiliary Power Outlet Connection | ||||
| 9. | See Figure 1 , and the wiring diagrams in the service manual. Separate the two halves of the gray connector [160] (2) that provides power to the auxiliary power outlet (1) on the instrument panel. NOTE DO NOT cut the wires on the main harness (or the heated hand grip harness on models so equipped). Cut ONLY the wires between the gray socket housing [160B] and the power outlet. | |||||
| 10. | Cut the wires between the gray socket housing [160B] and the power outlet. |
Splicing of wire leads is necessary in the installation of the GPS cradle to the motorcycle. Refer to the service manual for proper wire splicing procedures.
WARNINGBe sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a)
- Avoid directing heat toward any fuel system component. Extreme heat can cause fuel ignition/explosion resulting in death or serious injury.
- Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed.
- Always keep hands away from tool tip area and heat shrink attachment.
| 11. | Obtain the two sealed splice connectors (14) from the kit. Use one connector to splice the red wire on the Road Tech Zumo harness to the orange/red wires from the gray connector [160B] and the power outlet. Use the second connector to splice the black wire on the Zumo harness to the black wires from connector [160B] and the outlet. | |
| 12. | See Figure 2. Open the cover of the fuse holder (E) on the Buell Zumo harness. Plug the 2 Amp fuse (15) from the kit into the fuse holder, and close the cover. | |
| 13. | Position the flyscreen/windscreen assembly onto the left and right front modules. Install the six screws and washers removed earlier, and tighten to 1.1–1.4 N·m (10–12 in-lbs). | |
NOTICE Do not over-tighten bolts on battery terminals. Use recommended torque values. Over-tightening battery terminal bolts could result in damage to battery terminals. (00216a) | ||
| 14. | Thread the fastener through the negative (black) battery cable into the threaded hole of the negative (-) battery terminal. Tighten the fastener to 8–11 N·m (72–96 in-lbs). | |
| 15. | Apply a light coat of Harley-Davidson electrical contact lubricant (part number 99861-02), petroleum jelly or corrosion retardant material to the battery terminal. | |
| 16. | Refer to the owner's manual, and follow the instructions given to install the seat. |
WARNINGAfter installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
BUELL ZUMO UNIT INSTALLATION TO CRADLE MOUNT
- See Figure 2. Obtain the Buell Zumo unit (1) from the kit.
- Flip the lever (B) on the cradle mount (3) up. Flip the weather cap (A) open.
- Position the Road Tech Zumo unit into the cradle mount, and flip the lever (B) down.
- Use the security screwdriver (7) to tighten the security screw (C).
BUELL ZUMO UNIT OPERATION AND CARE
NOTE
Do not use solvent-based chemicals or waxes directly on the plastic or rubber components as they can affect the overall performance and appearance of the plastic and rubber.
Refer to the instructions that came with the Buell Zumo for operation and removal procedures. Remove the Buell Zumo unit from the motorcycle when not in use or when leaving the vehicle unattended. Store the Buell Zumo unit in the case (21) provided.
SERVICE PARTS
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Buell Zumo unit | Not sold separately |
2 | Cradle mount service kit (includes items 3 through 7) | 92379-08 |
3 |
| Not sold separately |
4 |
| See garmin.com |
5 |
| 8176M |
6 |
| See garmin.com |
7 |
| See garmin.com |
8 | Base, ram mount | See garmin.com |
9 | Arm, ram mount | See garmin.com |
10 | Post, ram mount | See garmin.com |
11 | Cap screw, T-27 TORX® button head, M6-1.0 x 40 mm long (2) | 4669M |
12 | Spacer, 0.297 inch (7.5 mm) thick (2) | 76008-05Y |
13 | Harness assembly, Buell Zumo | See garmin.com |
14 | Sealed splice connector, #14-16 AWG (blue) | 70586-93 |
15 | Fuse, blade type, 2A | 54305-98 |
16 | Clip, adhesive-backed (3) | 10271 |
17 | Wire tie (10) | 10006 |
18 | Earphone Kit (includes items 19 and 20) | 91771-04 |
19 |
| Not sold separately |
20 |
| Not sold separately |
21 | Carrying case | 92156-08 |
22 | AC charger (not shown) | See garmin.com |
23 | PC/USB cable (not shown) | See garmin.com |
24 | Audio cable (not shown) | Not sold separately |
25 | User's manual, Buell Zumo (not shown)) | See garmin.com |
Reference items mentioned in text: | ||
A | Weather cap | |
B | Lever | |
C | Security screw | |
D | Round four-pin DIN connector on harness | |
E | Fuse holder on harness | |
Figure 2. Service Parts, Buell Zumo Global Positioning System (GPS) Kit